Wired pipe coupler connector

ABSTRACT

A connector for use in connecting a communication element to a transmission line in a wired pipe segment includes a first female end adapted to surround and make electrical contact with a coupler connection that extends away from a communication element of the coupler; a second female end adapted to receive an inner conductor of a coaxial cable; and an inner connection element formed on an inner surface of the connector adapted to electrically connect the coupler connection and the inner conductor, the inner connection element formed such that it does not completely surround at least one of the inner conductor and the coupler connection.

BACKGROUND

During subterranean drilling and completion operations, a pipe or otherconduit is lowered into a borehole in an earth formation during or afterdrilling operations. Such pipes are generally configured as multiplepipe segments to form a “string”, such as a drill string or productionstring. As the string is lowered into the borehole, additional pipesegments are coupled to the string by various coupling mechanisms, suchas threaded couplings.

Various power and/or communication signals may be transmitted throughthe pipe segments via a “wired pipe” configuration. Such configurationsinclude electrical, optical or other conductors extending along thelength of selected pipe segments. The conductors are operably connectedbetween pipe segments by a variety of coupling configurations.

One such coupling configuration includes a threaded male-femaleconfiguration often referred to as a pin box connection. The pin boxconnection includes a male member, i.e., a “pin” that includes anexterior threaded portion, and a female member, i.e., a “box”, thatincludes an interior threaded portion and is configured to receive thepin in a threaded connection.

Some wired pipe configurations include a transmission device mounted onthe tip of the pin as well as in the box end. The transmission device,or “coupler,” can transmit power, data or both to an adjacent coupler.The coupler in the pin end is typically connected via a coaxial cable tothe coupler in the box end.

BRIEF DESCRIPTION

According to one embodiment, a wired pipe segment is disclosed. Thesegment includes a body extending from a box end to a pin end and acoupler located in one of the box and pin ends. The coupler includes acommunication element and a coupler connection in electricalcommunication therewith and extending away from the communicationelement. The segment also includes a transmission line extending awayfrom the coupler towards the other of the box and pin end, thetransmission line including an inner conductor surrounded by adielectric material, the inner conductor extending beyond an end of thedielectric material. The segment also includes a hollow connector thatelectrically connects the coupler to the transmission line, the hollowconnector including first and second female ends that respectivelyreceive the inner conductor and a portion of a coupler connection and aninner connection element formed on an inner surface of the hollowconnector that electrically connects the inner conductor and the portionof a coupler connection, wherein the inner connection element is formedsuch that it does not completely surround at least one of the innerconductor and the portion of a coupler connector.

Also disclosed is a connector for use in connecting a communicationelement to a transmission line in a wired pipe segment. The connectorincludes a first female end adapted to surround and make electricalcontact with a coupler connection that extends away from a communicationelement of the coupler; a second female end adapted to receive an innerconductor of a coaxial cable; an inner connection element formed on aninner surface of the connector adapted to electrically connect thecoupler connection and the inner conductor, the inner connection elementformed such that it does not completely surround at least one of theinner conductor and the coupler connection.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way.With reference to the accompanying drawings, like elements are numberedalike:

FIG. 1 depicts an exemplary embodiment of a wired pipe segment of a welldrilling and/or logging system;

FIG. 2 depicts an exemplary embodiment of a box connector of the segmentof FIG. 1;

FIG. 3 depicts an exemplary embodiment of a pin connector of the segmentof FIG. 1;

FIG. 4 is a partial side view of a coupler connected to a transmissionline via a connector according to one embodiment;

FIG. 5 is perspective view connector according to one embodiment;

FIG. 6 is a cut-away perspective view of the connector of FIG. 5;

FIG. 7 is a cut-away perspective view of another embodiment of aconnector; and

FIG. 8 shows an example of a capacitor made on an internal portion ofthe connector of FIG. 7.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosedsystem, apparatus and method are presented herein by way ofexemplification and not limitation with reference to the Figures.

Referring to FIG. 1, an exemplary embodiment of a portion of a welldrilling, logging and/or production system 10 includes a conduit orstring 12, such as a drillstring or production string, that isconfigured to be disposed in a borehole for performing operations suchas drilling the borehole, making measurements of properties of theborehole and/or the surrounding formation downhole, or facilitating gasor liquid production.

For example, during drilling operations, drilling fluid or drilling“mud” is introduced into the string 12 from a source such as a mud tankor “pit” and is circulated under pressure through the string 12, forexample via one or more mud pumps. The drilling fluid passes into thestring 12 and is discharged at the bottom of the borehole through anopening in a drill bit located at the downhole end of the string 12. Thedrilling fluid circulates uphole between the string 12 and the boreholewall and is discharged into the mud tank or other location.

The string 12 may include at least one wired pipe segment 14 having anuphole end 18 and a downhole end 16. As described herein, “uphole”refers to a location near the point where the drilling started relativeto a reference location when the segment 14 is disposed in a borehole,and “downhole” refers to a location away from the point where thedrilling started along the borehole relative to the reference location.It shall be understood that the uphole end 18 could be below thedownhole end 16 without departing from the scope of the disclosureherein.

At least an inner bore or other conduit 20 extends along the length ofeach segment 14 to allow drilling mud or other fluids to flowtherethrough. A transmission line 22 is located within the wired segment14 to provide protection for electrical, optical or other conductors tobe disposed along the wired segment 14. In one embodiment, thetransmission line 22 is a coaxial cable. In another embodiment, thetransmission line 22 is formed of any manner of carrying power or data,including, for example, a twisted pair. In the case where thetransmission line 22 is a coaxial cable it may include an innerconductor surrounded by a dielectric material. The coaxial cable mayalso include a shield layer that surrounds the dielectric. In oneembodiment, the shield layer is electrically coupled to an outerconductor that may be formed, for example, by a rigid or semi-rigid tubeof a conductive material.

The segment 14 includes a downhole connection 24 and an upholeconnection 26. The segment 14 is configured so that the upholeconnection 26 is positioned at an uphole location relative to thedownhole connection 24. The downhole connection 24 includes a malecoupling portion 28 having an exterior threaded section, and is referredto herein as a “pin end” 24. The uphole connection 26 includes a femalecoupling portion 30 having an interior threaded section, and is referredto herein as a “box end” 26.

The pin end 24 and the box end 26 are configured so that the pin end 24of one wired pipe segment 14 can be disposed within the box end 26 ofanother wired pipe segment 14 to effect a fixed connection therebetweento connect the segment 14 with another adjacent segment 14 or otherdownhole component. In one embodiment, the exterior of the male couplingportion 28 and the interior of the female coupling portion 30 aretapered. Although the pin end 24 and the box end 26 are described hashaving threaded portions, the pin end 24 and the box end 26 may beconfigured to be coupled using any suitable mechanism, such as bolts orscrews or an interference fit.

In one embodiment, the system 10 is operably connected to a downhole orsurface processing unit which may act to control various components ofthe system 10, such as drilling, logging and production components orsubs. Other components include machinery to raise or lower segments 14and operably couple segments 14, and transmission devices. The downholeor surface processing unit may also collect and process data generatedby the system 10 during drilling, production or other operations.

As described herein, “drillstring” or “string” refers to any structureor carrier suitable for lowering a tool through a borehole or connectinga drill bit to the surface, and is not limited to the structure andconfiguration described herein. For example, a string could beconfigured as a drillstring, hydrocarbon production string or formationevaluation string. The term “carrier” as used herein means any device,device component, combination of devices, media and/or member that maybe used to convey, house, support or otherwise facilitate the use ofanother device, device component, combination of devices, media and/ormember. Exemplary non-limiting carriers include drill strings of thecoiled tube type, of the jointed pipe type and any combination orportion thereof. Other carrier examples include casing pipes, wirelines,wireline sondes, slickline sondes, drop shots, downhole subs, BHA's anddrill strings.

Referring to FIGS. 2 and 3, the segment 14 includes at least onetransmission device 34 (also referred to as a “coupler” herein) disposedtherein and located at the pin end 24 and/or the box end 26. Thetransmission device 34 is configured to provide communication of atleast one of data and power between adjacent segments 14 when the pinend 24 and the box end 26 are engaged. The transmission device 34 may beof any suitable type, such as an inductive coil, direct electricalcontacts and an optical connection ring. The coupler may be disposed atthe inner or outer shoulder. Further, the transmission device 34 may bea resonant coupler. The each of these types of couplers shall bereferred to as including a communication element that allows it tocommunicate a signal to another coupler. It shall be understood that thetransmission device 34 could also be included in a repeater elementdisposed between adjacent segments 14 (e.g, within the box end). In sucha case, the data/power is transmitted from the transmission device inone segment, into the repeater. The signal may then be passed “as is,”amplified, and/or modified in the repeater and provided to the adjacentsegment 14.

Regardless of the configuration, it shall be understood that eachtransmission device 34 can be connected to one or more transmissionlines 22. Embodiments disclosed herein are directed to a connector thatis used to connect a transmission device to a transmission line. Theconnection could be galvanic or capacitive, for example. The term“direct” as used with respect to a connection shall include a galvanicconnection.

In more detail, and referring now to FIG. 4, a transmission device 34 isshown coupled to a transmission line 22 by a connector 100. Theillustrated transmission line 22 is a coaxial cable that includes aninner conductor 102 surrounded by a dielectric material 104. Thetransmission line 22 may also include an optional shield layer 108 thatcould be formed, for example, by a braided metal or metal foil layer.Regardless of how formed, if present, the shield layer 108 may besurrounded by an optional insulating layer 109 or may be electricallycoupled to an outer conductor 110 in one embodiment. The outer conductor110 can be rigid or semi-rigid and is formed of metal in one embodiment.The outer conductor 110 can extend the entire length of the transmissionline 22 (e.g., from one coupler 34 at one end of a drill pipe segment toanother coupler 34 at another end of the drill pipe segment). As analternative, the outer conductor 110 may only surround regions of thetransmission line 22.

Of course, the exact configuration of the transmission line could bevaried. For instance, the inner conductor 102 could be formed by atleast two electrically connected wires or a twisted pair and/or theshield layer 108 could be omitted. In one embodiment, the transmissionline 22 is fixedly attached to the outer conductor 110, for example, bywelding or otherwise connecting the transmission line 22 to the outerconductor 110. In all of the embodiments that follow it shall be assumed(if not explicitly illustrated) that the transmission line 22 issurrounded, at least at its ends, by an outer conductor and that the twoare fixedly coupled to one another at least over a part of the length ofthe outer conductor

While not illustrated it shall be understood that the outer conductor110 can be located within a gun drilled section of the walls of thesegments 14 (FIG. 1). In one embodiment, the outer conductor 110 isfixed within the segments.

As illustrated, a connector 100 electrically connects the coupler 34 tothe transmission line 22. Disclosed below are alternative connectors.Each connector embodiment is given a different reference numeral (e.g.,100, 200, etc.) but shall generally be referred to a connector. All ofthe connectors disclosed herein can be formed in different lengths toaccommodate for segment 14 length differences that may occur.

As illustrated in FIG. 4, the coupler 34 includes a coupler connection120 that extends away from the communication element 124 of the coupler34. A portion 120 a of the coupler connection 120 is shown passingthrough and extending beyond an optional sealing region 126. The sealregion (or stack) 126 provides for seal between the coupler connection120 and the outer conductor 110.

The portion 120 a, in one embodiment, extends into the coupler connector100. At the opposite end of the coupler connector 100 and end 102 a ofthe inner conductor 102 a extends into the coupler connector 100. Aninternal connection element 130 located on an inner surface of thecoupler connector 100 electrically connects portions 120 a and 102 a. Inthis manner, the coupler 34 may receive electrical signals from, andprovide electrical signals to, the inner conductor 102. As one ofordinary skill will understand, this may allow for a signal at a coupler34 at one end of a segment 14 to be conveyed to another coupler atanother end of the segment 14. Of course, intervening structures (e.g.,repeaters) may be disposed between the couplers on either end of thesegment 14. As shown, the internal connection element 130 is a solidstrip of material. Of course, and as shown below, such is not requiredand breaks may be introduced into the internal connection element 130and, in some cases, passive elements such as inductors or capacitors maybe formed either in the break or such that they connector portions ofthe internal connection element 130 on either side of a break.

FIG. 5 shows a perspective view of a coupler connector 100. The couplerconnector 100 is formed of two half shells portions 140 a and 140 bthat, when joined, form a hollow tube. Electrical elements such as theinner conductor 102 and the coupler connection 120 may be inserted intoopposite ends (134, 136) of the coupler connector 100 and electricallycoupled to one another by internal connection element 130. The halfshell portions 140 a, 140 b could for example be made of PEEK, PFTE,ceramic or any other material that is nonconductive.

As illustrated in FIG. 6, one of the half shells (in this case 140 a)has an internal connection element 130 formed on an inner surface 142 ofa trough 144 or other passage way formed therein. In one embodiment, theinternal connection element 130 is thin conductive (e.g., metallic)layer formed by Laser Direct Structuring (LDS) Technology. In oneembodiment, the internal connection element 130 is formed on only onehalf shell. In one embodiment, the internal connection element 130 isformed on both. In either, the internal connection element 130 may beformed such that is does not surround any element disposed within thetrough 142. For example, the internal connection element 130 may beformed such that when the half shells 140 a, 140 b are coupled together(as in FIG. 5) and the inner conductor 102 and the coupler connection120 are inserted into opposite ends (134, 136) of the coupler connector100 it does not surround either the inner conductor 102 or the couplerconnection 120. Of course, in one embodiment, one or both of the innerconductor 102 and the coupler connection 120 could be completelysurrounded. For example, in one embodiment, the internal connectionelement 130 could be formed such that it surrounds the couplerconnection 120 but not the inner conductor 102.

Forming an internal connection element 130 may allow for the use ofinexpensive high conductive material to be used for the electriccontacts. Another advantage is that the internal connection element maybe formed such that it includes passive elements such as capacitors orinductors in its conduction path.

For example, FIG. 7 shows a portion of another embodiment of a connector300. As illustrated, only one half shell 160 a is shown. This half shellcould be joined, for example, to half shell 140 b to form a hollow tubeas generally described above. In this embodiment, a passive element 150is introduced into the conductive path of the internal connectionelement 130. The element may be, for example, a resistor, a capacitor,an inductor, or another electrical element that may be formed by LDS.Further, more than one element may be provided to form, for example, animpedance matching circuit if such is required. A comparison of FIG. 6and FIG. 7 illustrates that the internal connection element 130 mayextend to different locations within the connector 100/200. A particularlocation is not required as long as the internal connection element 130can be electrically coupled to another element disposed at leastpartially within the connector 100/200.

FIG. 8 shows an example of a passive element 150 formed as a capacitor.The capacitor includes one or more fins 170 a/b formed by LDS that serveas capacitor plates. As illustrated, the “input fins” are designated byreference numerals followed by an “a” and the “output fins” aredesignated by reference numerals followed by a “b”. The input and outputfins may be made of any type of metallic or other conductive material(e.g., carbon) and may the same as each other or different. In oneembodiment, the fins are made of copper or copper alloy. The innersurface 200 of the connector serves to separate the plates and mayserve, in combination with air, as dielectric between the plates. Ofcourse, the passive elements disclosed could be formed in any of theconnectors disclosed herein.

In any of the embodiments disclosed here, the half shells may be formedsuch that impacts of force on the electrical connector disposed ineither end thereof are handled while still creating a reliableconnection in a harsh drilling environment that may include superimposedvibrations. The options to create this clamping force are various andcannot all be described in here, but here are some ideas: crimping ofthe sleeve, using shape memory material for the sleeve, inserting clampsor shims.

In support of the teachings herein, various analyses and/or analyticalcomponents may be used, including digital and/or analog systems. Thesystem may have components such as a processor, storage media, memory,input, output, communications link (wired, wireless, pulsed mud, opticalor other), user interfaces, software programs, signal processors(digital or analog) and other such components (such as resistors,capacitors, inductors and others) to provide for operation and analysesof the apparatus and methods disclosed herein in any of several mannerswell-appreciated in the art. It is considered that these teachings maybe, but need not be, implemented in conjunction with a set of computerexecutable instructions stored on a computer readable medium, includingmemory (ROMs, RAMs), optical (CD-ROMs), or magnetic (disks, harddrives), or any other type that when executed causes a computer toimplement the method of the present invention. These instructions mayprovide for equipment operation, control, data collection and analysisand other functions deemed relevant by a system designer, owner, user orother such personnel, in addition to the functions described in thisdisclosure.

One skilled in the art will recognize that the various components ortechnologies may provide certain necessary or beneficial functionalityor features. Accordingly, these functions and features as may be neededin support of the appended claims and variations thereof, are recognizedas being inherently included as a part of the teachings herein and apart of the invention disclosed.

While the invention has been described with reference to exemplaryembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications will be appreciated by those skilled in theart to adapt a particular instrument, situation or material to theteachings of the invention without departing from the essential scopethereof. Therefore, it is intended that the invention not be limited tothe particular embodiment disclosed as the best mode contemplated forcarrying out this invention, but that the invention will include allembodiments falling within the scope of the appended claims.

What is claimed is:
 1. A wired pipe segment comprising: a body extending from a box end to a pin end; a coupler located in one of the box and pin ends, the coupler including a communication element and a coupler connection in electrical communication therewith and extending away from the communication element; a transmission line extending away from the coupler towards the other of the box and pin end, the transmission line including an inner conductor surrounded by a dielectric material, the inner conductor extending beyond an end of the dielectric material; and a hollow connector that electrically connects the coupler to the transmission line, the hollow connector including first and second female ends that respectively receive the inner conductor and a portion of a coupler connection and an inner connection element formed on an inner surface of the hollow connector that electrically connects the inner conductor and the portion of a coupler connection, wherein the inner connection element is formed such that it does not completely surround at least one of the inner conductor and the portion of a coupler connector.
 2. The wired pipe segment of claim 1, wherein the hollow connector is formed by a first half shell and second half shell joined together.
 3. The wired pipe segment of claim 2, wherein the connection element is formed as a conductive strip deposited by laser direct structuring on the first half shell.
 4. The wired pipe segment of claim 2, wherein the first and second half shells are formed of a non-conductive material.
 5. The wired pipe segment of claim 1, wherein the coupler includes a seal stack surrounding the coupler connection.
 6. The wired pipe segment of claim 1, wherein the coupler is one of: an inductive coupler, a capacitive coupler, a direct connection and a resonant coupler.
 7. The wired pipe segment of claim 1, wherein the inner connection element includes an electrical element formed between the first and second female ends.
 8. The wired pipe segment of claim 7, wherein the electrical element is a capacitor.
 9. A connector for use in connecting a communication element to a transmission line in a wired pipe segment, the connector comprising: a first female end adapted to surround and make electrical contact with a coupler connection that extends away from a communication element of the coupler; a second female end adapted to receive an inner conductor of a coaxial cable; and an inner connection element formed on an inner surface of the connector adapted to electrically connect the coupler connection and the inner conductor, the inner connection element formed such that it does not completely surround at least one of the inner conductor and the coupler connection.
 10. The connector of claim 9, wherein the hollow connector is formed by a first half shell and second half shell joined together.
 11. The connector of claim 10, wherein the connection element is formed as a conductive strip deposited by laser direct structuring on the first half shell.
 12. The connector of claim 9, wherein the first and second half shells are formed of a non-conductive material.
 13. The connector of claim 9, wherein the inner connection element includes an electrical element formed between the first and second female ends.
 14. The connector of claim 13, wherein the electrical element is a capacitor. 